Hot tub cover including modular core

ABSTRACT

A hot tub cover including at least one core module including a jacket and at least one core module within the jacket. Each core module is fabricated from a plurality of rigidly interconnected core elements. In the disclosed embodiment, the core elements are extruded and include dovetail elements at their edges enabling the core elements to slide together.

BACKGROUND OF THE INVENTION

The present invention relates to a cover for spas, hot tubs, and thelike and more particularly to an improved core for such covers.

In order to provide insulation, limit pollution, and reduce the risk ofaccidents, it is desirable to cover the open top of a spa or hot tub.For example, one particularly effective cover having a rigid plasticcore is illustrated and described in U.S. Publication 2005/0086731 datedApr. 28, 2005 and entitled “Cover for Hot Tub, Spa, or the Like.” Thiscover includes two separate core halves and a watertight jacketenclosing the core halves and providing a hinge between the two halves.Therefore, the core halves can fold together to aid in removal of thecover.

Although a notable advance in the art, this cover is not without itdrawbacks. First, the two large core halves exceed the size limits ofconventional carriers (e.g. United Parcel Service and the U.S. PostalService), which makes shipping by conventional carriers expensive. Thisadditional costs reduces the effective practical market for the coverboth domestically and internationally.

SUMMARY OF THE INVENTION

The aforementioned problems are overcome by the present inventionwherein a cover for a hot tub or spa includes one or more core moduleseach including a plurality of rigidly interconnected core elements. Thecore elements can be separated for shipping. The core elements can bereadily assembled following shipping into the one or more core modules.

The disassembled core elements can be easily and economically shipped.For example, the core elements can be shipped as a compact stack ofunassembled elements. The compact stack typically will not exceed thenormal-shipping-cost size limitations of common carriers, and thereforewill be accorded normal shipping costs. Alternatively, the unassembledelements can placed within a hot tub or spa that is being shipped. Whenthe elements are shipped within a hot tub, the potential for damageduring shipping is significantly reduced.

After shipping, the elements are easily rigidly interconnected to formone or more core modules of the hot tub cover. The assembly can beaccomplished by either a professional installer or a consumer. A jacketalso is included with the shipped core elements so that the core modulescan be enclosed within the jacket to complete the cover.

These and other objects, advantages, and features of the invention willbe more fully understood and appreciated by reference to the descriptionof the current embodiment and the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of the hot tub cover of the presentinvention installed on a hot tub.

FIG. 2 is a fragmentary section view taken along line 2-2 of the hot tubcover including die adjacent core modules and the jacket.

FIG. 3 is a perspective view of one of the core modules with the coreelements staggered from one another.

FIG. 4 is a side view of the cover with portions of the vinyl jacketremoved to reveal the core module.

FIG. 5 is a sectional view of a core element with a male dovetailelement and a female dovetail element.

FIG. 6 is a top plan view of the core elements placed within the hot tubfor shipping.

FIG. 7 is a perspective view of the core elements stacked and packagedfor shipping.

DESCRIPTION OF THE CURRENT EMBODIMENT

A hot tub cover constructed in accordance with a current embodiment ofthe invention is illustrated in the drawings and generally designated12. The cover 12 generally includes a vinyl jacket 14 and two plasticcore modules 16. Each core module 16 in turn includes a plurality ofrigidly interconnected elements 70. The vinyl jacket 14 encloses thecore modules 16. The jacket 14 includes an integral living hinge 22 thatenables the cover 12 to fold onto itself (i.e. “in half”).

As illustrated in FIG. 1, the cover 12 is covers a hot tub 10. Althougha hot tub is shown in the drawings, the cover is equally usable with aspa or any other unit containing water. The use of “hot tub” in thisspecification is intended to include spas and such other units. Theillustrated hot tub 10 is rectangular, but the hot tub could be anyother desired shape. The cover 12 is shaped and dimensioned to fit overthe entire opening 11 of the hot tub 10.

The jacket 14 is well known to those skilled in the art. In the currentembodiment, the jacket 14 is made of a marine grade vinyl, or anotherhigh-strength waterproof fabric. The jacket 14 is large enough toenclose the rigid core modules 16, and the jacket includes an integralliving hinge 22, a front edge 24, a rear edge 26, and a pair of oppositelateral edges 28. In the current embodiment, the jacket 14 is capable ofbeing opened and closed to receive and to enclose the core 16 byconventional means such as a zipper or similar mechanism (not shown).The jacket 14 may also include attachments (not shown) such as snapsthat attach the cover 12 to the hot tub 10 when the cover 12 isinstalled, and/or straps that facilitate grasping and movement of thecover.

Each core module 16 is comprised of a plurality of rigidlyinterconnected core elements 70. In the current embodiment, each coremodule 16 is comprised of four such core elements 70 a, 70 b, 70 c, and70 d. The core element 70 a is adjacent the hinge 22 and is the thickestcore element. The core element 70 d is remote from the hinge 22 and isthe thinnest core element. The collective upper surfaces of the coreelements 70 slope from the hinge 22 to the lateral edge 28 so that rainand other water will run off the cover 12.

Each element 70 is currently made from a thermoformable polymer such asABS, HDPE, or PVC. Another other suitable material also may be used. Theelement 70 is shaped to rigidly interconnect with other elements to formthe core 16. Each element 70 extends from an inner edge 36 to an outeredge 37. Each core module 16 a, 16 b extends from an inner edge 20 to anouter edge 21. The outer edge 21 is adjacent the outer edge 28 of thejacket 14. The elements 70 are substantially parallel to the hinge 22.The front edge 36 and the rear edge 37 of each element 70 form a portionof the front edge 42 and the rear edge 44 respectively of the core 16.The front edge 42 and rear edge 44 are adjacent the front 24 and rear 26edges respectively of the jacket 14.

In tire current embodiments each element 70 includes an upper surface30, a lower surface 32, a front edge 36, a rear edge 37, and a pluralityof ribs 18 extending therebetween. The ribs 18 extend from the frontedge 36 to the rear edge 37 of the core 16. Further in the currentembodiment, each core element 70 is extruded, so that each core elementis a single unitary piece. Other suitable manufacturing techniques alsomay be used.

In the current embodiment, each core element 70 includes at least onedovetail element 80 f or 80 m. The core element 70 a includes a femaledovetail element 80 f. The core elements 70 b and 70 c each include botha male dovetail element 80 m and a female dovetail element 80 f. Thecore element 70 d includes a male dovetail element 80 m. The dovetailelements or dovetails 80 extend from the front edge 36 to the rear edge37 of the core 16. The shape, dimensions, and tolerances of the male andfemale dovetails 80 of each core element 70 correspond to thecorresponding dovetails of the adjacent element(s) such that all theelements slidably interconnect to form the core 16. The dovetails 80provide a means of rigidly interconnecting the core elements in asimple, efficient, and low-cost construction. It is envisioned thatother known means of rigidly interconnecting could be used in place ofthe dovetails.

Optionally, the open spaces 40 between the ribs 18 can be filled with aninsulating foam (not shown) or other insulating material to furtherenhance the thermal properties of the cover 12.

To interconnect two adjacent core elements 70, the male dovetail 80 m ofone element 70 is aligned with the female dovetail 80 f of the otherelement. The two elements are then slid longitudinally relative to oneanother until the front edges 36 and rear edges 37 are aligned. Thisprocess is repeated for multiple elements to form the core 16.

The core module 16 may be a replacement for a previous core componentsuch that it is inserted into an existing jacket, or the core module 16may be inserted into a brand new jacket 14 of the desired dimensions.The jacket 14 is closed about the core 16 and placed over the opening ofa hot tub 10. Removal of the cover 12 consists of folding the cover 12back about the hinge 22 and pulling the cover off the hot tub 10.

The multiple element design allows the unassembled elements 90 to beseparated and placed or stacked within the hot tub 10 during shipping.Spacers or an abutting formation can be utilized in placing or stackingthe unassembled elements 90. Currently, the core elements 70 are stackedalternately upper surface 30 to upper surface 30 with front edges 36 andinner edges 60 substantially aligned such that the stack 80 forms asubstantially straight stack. The stacked elements may be wrapped instretch wrap, shrink wrap, cardboard, or some other shipping material tokeep the stacked elements 90 stacked and to minimize the potential fordamage to the hot tub 10.

A hot tub cover kit includes a water resistant jacket 14 and multipleelements 70 capable of being rigidly interconnected to form the coremodule 16.

Regardless of die shipping configuration and method, the core elements70 must assembled following shipping to form die core module 16. Thecore module(s) 16 then are slid into the cover 14, and the cover isclosed using the zipper or other closure mechanism.

The present invention provides several advantages. First the coreelements 70 can be shipped more easily and more economically thanprevious covers. Second, the core elements 70 can be placed inside a hottub for shipment, further reducing costs and also reducing die potentialfor damage to the core elements.

The above descriptions are those of current embodiments of theinvention. Various alterations and changes can be made without departingfrom the spirit and broader aspects of the invention as defined in theappended claims, which are to be interpreted in accordance with theprinciples of patent law including the doctrine of equivalents. Anyreference to claim elements in the singular, for example, using thearticles “a,” “an,” “the” or “said,” is not to be construed as limitingthe element to the singular.

1. A hot tub cover comprising: at least one core module including aplurality of rigidly interconnected core elements, each core elementbeing a single unitary piece including connector means for connectingthe core element to at least one adjacent core element; and a jacketenclosing said core.
 2. The hot tub cover of claim 1 wherein eachelement includes upper and lower surfaces spaced from one another. 3.The hot tub cover of claim 1 further comprising: at least two of saidcore modules; and a hinge interconnecting said core modules.
 4. The hottub cover in claim 3 wherein each core module includes a hinged edge anda peripheral edge, said upper surfaces collectively sloping downwardlyfrom said hinged edge to said peripheral edge.
 5. The hot tub cover ofclaim 1 wherein said core elements are slidably interconnected by maleand female dovetails.
 6. The hot tub cover of claim 2 wherein each coreelement further includes a plurality of spaced ribs extending betweensaid upper and lower surfaces of said element, said spaced ribs defininga plurality of openings between said upper and lower surfaces.
 7. Thehot tub cover of claim 6 further comprising an insulating materialbetween said ribs.
 8. A hot tub cover core module comprising a pluralityof rigidly interconnected core elements.
 9. The hot tub cover coremodule of claim 8 wherein each of said core elements is a single unitarypiece including connector means for connecting said core element to atleast one adjacent core element.
 10. The hot tub cover core module ofclaim 9 wherein each connector means comprises a dovetail component. 11.The hot tub cover core module of claim 8 wherein each core elementincludes upper and lower surfaces spaced from one another.
 12. The hottub cover core module in claim 11 wherein each core element includes aplurality of spaced ribs extending between said upper and lower surfacesof said element said spaced ribs defining a plurality of openingsbetween said upper and lower surfaces.
 13. The hot tub cover core modulein claim 12 further comprising an insulating material between said upperand lower surfaces.
 14. The hot tub cover core module in claim 11wherein said upper and lower surfaces of each core element arenon-parallel.
 15. A hot tub cover kit comprising: a plurality of coreelements adapted to be rigidly interconnected to form a core module; anda water resistant jacket.
 16. The hot tub cover kit of claim 15 wherein:said elements have non-parallel upper and lower surfaces; and saidelements are arranged into a substantially straight stack with saidelements alternating.
 17. A method of manufacturing a hot tub covercomprising the steps of: providing a plurality of core elements adaptedto be rigidly interconnected; rigidly interconnecting the core elementsto provide a core module; and enclosing the core module within a jacket.18. The method of claim 17 wherein each of the core elements is a singlepiece.
 19. The method of claim 18 wherein said providing step includesextruding each of the core elements.
 20. The method of claim 17 whereinthe interconnecting step includes: aligning a male dovetail of a firstelement with a female dovetail of a second element; and sliding the maleand female dovetails relative one another.
 21. A method of shipping ahot tub cover comprising the steps of: providing a hot tub having aninterior; placing a plurality of core elements within the interior ofthe hot tub, the elements adapted to be rigidly interconnected to form acore module that cannot lit within the interior of the hot tub; shippingsaid hot tub with the core elements within the hot tub, whereupon theelements can be subsequently removed from the hot tub and rigidlyinterconnected into a core capable of covering the hot tub.
 22. Themethod of shipping of claim 21 wherein: the hot tub is rectangular; andsaid placing step includes placing the plurality of elements diagonallywithin the hot tub.
 23. The method of shipping of claim 21 wherein: eachcore element includes non-parallel upper and lower surfaces; and saidplacing step includes alternating the orientation of the elements sothat they form a substantially straight stack.
 24. The method of claim21 further comprising the step of: packaging said plurality of coreelements.
 25. The method of claim 21 wherein each core element includesat least one dovetail element adapted to interfit with a dovetailelement on another core element.
 26. A method of shipping a hot tubcover comprising the steps of: providing a plurality of core elementseach having planar, non-parallel upper and lower surfaces; stacking theplurality of core elements in alternating fashion to form asubstantially straight stack despite the non-parallel upper and lowersurfaces; packaging the stack; shipping the stack.
 27. The method ofclaim 26 wherein said providing step includes providing each coreelement with at least one dovetail element adapted to interfit with adovetail element on another core element.